part three of the bonnet works was to rectify rust along the wing edges, inner wing stiffeners and restore those sensuous curves
An E Type bonnet is without any doubt a graceful outer form, but is somewhat primitive in construction, creating multiple traps for debris which if left unattended will begin the slow and inevitable process of rust
a series of flanges are used to hold the 2 wing panels to the inner bonnet panel, which in the initial year or so of production were spot welded to the wings, and then subsequently held in place with Sikaflex
i knew my bonnet was not original but rather an earlier item as the flanges were spot welded
but in fact whether welded or bonded the rust problems are common to all....
this is the outside of one flange....
which was the result of this inner damage....
which meant I needed not only a new one of these....(hand crafted by Barry, with careful attention to matching the original bolt holes....)
but also need some of this...
at the lower rolled edges more rust had developed...these are a pain to repair as the rolled edge is unforgiving to unpick and re-roll....so if at all possible it is better to try and leave the edge alone and repair within....if possible....but sometimes it isn't....so a small, but time consuming series of processes is needed to repair...
where inner bonnet and outer wings meet along a curved junction more rust develops, usually the result of debris being flung off the wheels and forced into any crevice and seam.....
and more....
once all this had been repaired, and there were multiple cases of each type, there were 2 further matters needing attention
just about all bonnets seem to suffer damage to the extract louvres....so they needed careful straightening
and most old bonnets seem to suffer impact damage around the nose and the power budge.....
so hours of hammer and dolly work was needed to restore the curves but also ensure the sharp crease line of the power budge was reinstated..(early bonnets have a cleaner crease which makes them distinguishable from later versions and also new reproductions, so thesis essential in restoring an early car...
and the nose....
hours of careful work....just perfection.....
which only then allowed the wings and centre section to be mated to appreciate the further work which was going to be needed to ensure the paired edges would eventually be parallel but also to ensure a single compound curve was formed as the inner panel geometry flowed into the outer wing ....note how the return flanges are not at a right angle, they are curved in plan view and they are curved along their length....
all of this allowed the bonnet to be readied for a full trial assembly.....which back in the day was said to be allowed a working week for a 2 man team......that is with new panels....Barry was largely on his own....and the panels were far from factory fresh......
